Just a thought, you say when you checked the earth crown it was good.....but did you actually pull all the spades off and give them and the crown a clean?
Not with contact cleaner, go over all with fine sandpaper or emery cloth and make sure the spades are a secure fit, I had similar symptoms and visually mine looked ok but cleaning them up sorted it
1984 1.6TD T25 DIPPED BEAM RELAY
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Re: 1984 1.6TD T25 DIPPED BEAM RELAY
1987 single cab pickup 1.9 1Y